XLC 2nd Stage Service Manual.pdf - Aberdeen Watersports

XLC Second Stage Service & Repair Manual 5Disassembly ProceduresNOTE: Before performing any disassembly, refer to Table 4,which references all mandatory replacement parts. Theseparts must be replaced with new, and must not be reusedunder any circumstances - regardless of the age of theregulator or how much use it has received since it was lastserviced.Fig. 1 – Removing Purge CoverFig. 2 – Removal of End PlugCAUTION: To prevent damage to critical sealing surfaces,use only a plastic or brass O-ring removal tool (P/N 9440-22)when removing O-rings. Once an O-ring sealing surface hasbeen damaged, the part must be replaced with new in orderto prevent the possibility of leakage. DO NOT use a dentalpick, or any other type of steel instrument.1. While holding the inlet fitting(20) of the second stage securewith a 19mm open end wrench, apply 17mm (n") open-endwrench to the female fitting of the LP hose(16). Turn thefitting counter-clockwise to loosen and remove the hose fromthe second stage. Remove the O-rings(17&18) from the hoseand discard. Set the hose aside.2. Carefully snip the plastic mouthpiece clamp(26) and removethe mouthpiece(25) from the box bottom(22). Inspect themouthpiece to ensure it is free of any tears or cuts that maycause leakage of water into the second stage or other discomfort.Discard the mouthpiece or set it aside to be reused,depending on its condition.3. While holding the second stage secure, firmly grasp the collarof the front cover(3) which is seated over the sealed adjustmentport of the box bottom, opposite of the inlet side. Stretchthe collar over the adjustment port, and lift the front cover offthe box bottom until the opposite collar can be removed fromthe inlet fitting (see Fig. 1).4. If it is necessary, press out the stem of the purge button(2)from inside the front cover. Closely examine the front cover tocheck for any tears, distortion, deterioration, or other signs ofdamage. Replace it if found, or set it aside if it is in reusablecondition.5. Lift out the sealing ring(4) and diaphragm(5) from the boxbottom, and closely inspect the diaphragm to ensure that it isperfectly round and free of any tears, deterioration, or otherdamage. If deterioration or damage is found, discard thediaphragm and do not attempt to reuse.6. While squeezing the flanges of the end plug(28) together, pressthe end plug out so that it exits the box bottom (see Fig. 2).Remove and discard the O-ring(29), and closely examine theO-ring sealing surface of the end plug to check for any nicks orscratches. Discard if found, or set it aside if it is in reusablecondition.© 1999 Aqua Lung America, Inc.